file linking to the Tremec T3650
Contents
1. ROLL PIN ai REVERSE FORK 4 SHIFT P d A ea REVERSE FORK SHIFT ASS Y 34 amp 4 SHIFT Be 5 FORK SHIFT PAD 5 amp REV SHIFT RAIL Es 5 FORK SHIFT ASS Y 32 Remove the three detent plugs as shown 33 Position the three detent plugs springs and the de tents as indicated 22 L di d 34 Using a 5 32 inch drift and hammer remove the split 35 Remove the 1st amp 2nd fork and shift rail as indicated pin From the 1st amp 2nd fork and shift rail A m ay kk AS 36 Using a 5 32 inch drift and hammer remove the split 37 Remove the 3 amp 4th fork and rail as indicated pin from the 3 amp 4th fork and shift rail ux Iz f g ic i 38 Using 5 32 inch drift and hammer remove the split pin 39 Remove the reverse fork and rail as indicated from the reverse fork and shift rail EN 2 3 TR 3650 PRIMARY GEAR PARTS GROUP DISASSEMBLY 3 BLOCKER RING 3 4 SLEEVE 37 4 HUB SYNCHRO SPRING SYNCHRO INSERT SYNCHRO NF il 21 BLOCKER RING l 2M BLOCKER RING amp LINING ASS Y SNAP RING 2 BLOCKER RING 2 CLUTCH I SNAP RING TOP INSERT 2 GEAR SPEED REVERSE HUB SYNCHRO NEEDLE BEARING ASS Y SPRING SYNCHRONIZER THRUST WASHER 2 GEAR SPEED 3 GEAR BUSHING ASSY REVERSE SLEEVE rd n 3 GEAR SPEED REVERSE BLOCK2. M R Appropriate service methods and proper repair procedure are essential for the safe reliable operation of all motor vehicles as well as the personal safety of the individual doing the work This Manual provides general directions for accomplishing service and repair work with tested effective techniques Following them will help assure reliability There are numerous variations in procedures techniques tools and parts for servicing vehicles as well as in the skill of the individual doing the work This Manual cannot possibly anticipate all such variations and provide advice or cautions as to each Accordingly anyone who departs from the instructions provided in this Manual must first establish that he compromises neither his personal safety nor the vehicle integrity by his choice of methods tools or parts NOTES CAUTIONS amp WARNINGS IM As you read through the procedures you will come across NOTES CAUTIONS and WARNINGS Each one is there for a specific purpose NOTES give you added information that will help you to complete a particular procedure CAUTIONS are given to prevent you from making an error that could damage the vehicle WARNINGS remind you to be especially careful in those areas where carelessness can cause personal injury The following list contains some general WARNING that you should follow when you work on a vehicle Always wear safety glasses for eye protection
3. f m i umm m ma S dez ee T L Brie mr Pi g 3 Remove the control turret assembly as indicated 4 Rotate the transmission to a vertical position and remove the bolt and washer that hold the spring and plate 5 Using a 1 4 socket remove the bolts as shown 6 Remove the shift spring and plate as indicated 16 Wa cb wr Fa 7 Using a 5 32 inch drift and hammer drive the split pin downward as shown 10 Using a flat blade screwdriver separate the extension housing then remove the gearshift offset lever from the transmission case ff A rw i 11 Remove the assembly extension housing as shown 12 Using a snap ring plier remove the sensor speedometer snap ring as indicated 17 TR 3650 ja 13 Using the special tools remove the sensor 14 Using a magnet remove the ball as indicated speedometer as shown 16 Using a 5 32 inch drift and hammer remove the pin gear assembly as shown from the fifth gear shift fork 17 Remove the fifth gear shift fork and synchronizer cone 18 Using a 5 82 inch drift and hammer drive out the split along with the synchronizer assembly as shown pin then remove the 3 amp 4th shift gate as indicated 18 qallha Ts 19 Using a 5 32 inch drift and hammer drive out the split pin then remove the 1st amp 2nd shift gate V T
4. TET rie IB 15 86 Remove the sensor bolt as shown 87 Remove the sensor as indicated 88 Using a special tools remove the extensi n housing fluid seal as shown 88585858 NI 3 7 REASSEMBLY REVERSE GEAR TR 3650 1 Inspect the gear and bearing for wear or damage Install 2 Install the reverse idler gear assembly as indicated new as necessary 3 Install a new seal and the reverse idler shaft bolt as 4 Install the reverse switch as indicated shown F a 1 E ji f i ji LA l la tul F Wh ja i E d i um 5 If previously removed install the extension seal with the 6 Install the sensor as indicated proper seal driver KI M ad i Hh 7 Install the sensor bolt as shown 8 Install the fifth amp reverse lockout as indicated 10 Install the mainshaft in a support or vise with soft jaws or wood shaft front facing up as indicated 11 Install 1 amp 2 synchronizer assembly as shown 12 Using a special tool or press install the 118 2 synchronizer as indicated 39 TR 3650 13 Using a snap ring plier install the of 1 amp 2 hub snap 14 Install the second gear synchronizer blocker ring align ring as shown the blocking ringtabs with sinchronizer assembly 15 Install the second gear synchronizer outer cone as 16 Install the second gear syn
5. ic REVERSE IDLER GEAR SPRING SYNCHRO REVERSE SHAFT RAIL 5 HUB SYNCHRO BEARING TAPERED ROLLER CONE SNAP RING TOP INSERT BEARING TAPERED REVERSE SUPPORT SHAFT ROLLER CUP O RING BOLT TORX BOTTON HEAD 44 67 Remove the countershaft as shown 68 Remove the cone bearing as indicated 30 INPUT SHAFT DISASSEMBLV THRUST WASHER SHAFT THRUST BEARING BEARING POCKET INPUT SHAFT BEARING TAPERED ROLLER CONE BEARING TAPERED ROLLER CUP SHIM 69 Remove the input shaft as indicated 70 Remove the synchronizer blocking ring as shown 31 TR 3650 71 Remove the axial bearing as shown 72 Remove the input shaft needle bearing as shown 73 Using a special tool or a press remove the cone bearing from the input shaft as shown CASE PARTS GROUP DISASSEMBLV INTERLOCK SUPPORT TRANSMISSION CASE BREATHER SHIPTER NTERLOCK i CENTER a INTERLOCK PIN Se SHIPTER DRAIN PLUG DOWELL PIN CLUTCH HOUSING SWITCH ASS Y STUD CLUTCH BACKUP LAMP RELEASE PIN DOWELL ec DETENT PLUG ACTUATING SPRINGS DETENT TUB RETAINER BEARING BOLT METRIC HEX WASHER HEAD 74 Remove the cup bearing from the main drive as 75 Remove the shim bearing from the main drive as shown indicate 33 TR 3650 76 Remove the bearing cup from the counter shaft a
6. D WASHERS 1 Check surfaces of all washers Washers scored or reduced in thickness should be replaced E REVERSE IDLER GEAR ASSEMBLIES 1 Check for excessive wear from action of roller bearing F ASSEMBLIES CONTROL PARTS 1 Revise desgaste en donde asienta revise las ranuras de los topes y las horquillas revise los insertos de las horquillas reemplace los insertos si muestran huellas de desgaste G ASSEMBLIES CONTROL TURRET 1 When disassembled the turret check torreta revise si hay desgaste en el extremo bajo de la palanca en el conjunto del dedo accionador de los cambios reemplace la parte con desgaste excesivo H BEARING CUP 1 Check si las tazas tienen desgaste reemplace las tazas que est n danadas 1 OIL SEALS 1 Check oil in input shaft and rear bearring cover If sealing action of lip has been destroyed replace seal J SYNCHRONIZER ASSEMBLY 1 Check synchronizer for burrs uneven and excessive wear at contact surface and metal particles 2 Check blocker insert for excessive wear or looseness 14 ENNNNNU INSPECTION 3 Check synchronizer contac surfaces on the synchro nizer rings for wear Make sure that case interiors and housings are clean It is important that dirt and other foreign materials are kept out of the transmission during reassembly Dirt is an abrasive and can damage polished surfaces of bearing and washers Use certain precau
7. drivers instructions and other forms service information for theses and other TREMEC transmission are available upon request On any repair or parts replacement always use original TREMEC parts according to the corresponding Service part Catalog The use non original parts may endanger the operation and performance of the transmission TRANSMISIONES Y EQUIPOS MECANICOS S A DE C V DOES NOT GUARANTEE service parts or failures resulted for a misuse or not being provided by an authorized TREMEC distributor A product literature order from service bulletins detailing information on product improvements repair procedures and other service related subjects can be obtained by writing to the following address NOMENCLATURE PLANT AND GENERAL OFFICES Letter designations Number designations TRANSMISIONES Y EQUIPOS MECANICOS S A DE C V Av 5 de Febrero No 2115 C P 76120 Quer taro Qro TR 3650 B TREMEC Design Level Design Forward speeds x10 Capacity nominal lbs ft TR 3650 TRANSMISSION TR 3650 PARTS 1 1 MAGNET 2 1 ROLL PIN 3 8 ROLL PIN 4 1 SNAP RING SPEEDOMETER 5 1 TAG IDENTIFICATION 6 1 CENTER INTERLOCK PIN 7 2 SHIFTER INTERLOCK 8 1 BEARING ROLLER CUP 9 2 ROLLER BEARING SELECTOR ARM 10 1 SPRING INHIBITOR 11 14 BOLT METRIC HEX WASHER HD 12 2 NYLON STOP 13 1 BEARING INPUT SHAFT POCKET 14 1 THRUST BEARING ASS Y 15 1 THRUST WASHER SHAFT PILOTED 16 SNAP RING 2 30
8. lll Use safety stands whenever a procedure requires you to be under the vehicle with the vehicle jacked up Be sure that the ignition switch is always in the OFF position unless otherwise required by the procedure Set the parking brake when working on the vehicle It should be in REVERSE engine OFF or NEUTRAL engine ON unless instructed otherwise for a specific operation Place wood blocks 4 X4 or larger to the front and rear surfaces of the tires to provide further restraint from inadvertent vehicle movement Bl Operate the engine only in a well ventilated area to avoid the danger of carbon monoxide Keep yourself and your clothing away from the moving parts when the engine is running especially the fan and drive belts o prevent serious burns avoid contact with hot metal parts such as the radiator exhaust manifold tail pipe catalytic converter and muffler Do not smoke while working on the vehicle BI To avoid injury always remove rings watches loose hanging jewelry and loose clothing before beginning to work on a vehicle Tie long hair securely behind the head Keep hands and other objects clear of the radiator fan blades Electric cooling fans can start to operate at any time by an increase in under hood temperatures even though the ignition is in the OFF position Therefore care should be taken to ensure that the electric cooling fan is completely disconnected when working under the hood
9. Thoroughly clean all exposed surfaces then check for leaks Vent or breather clogged Remove vent tube and clean or replace Too much or improper lubricant Remove fill plug to check for excess or drain an replace Loose bolts at sealing faces Torque bolts to specifications Improperly applied sealant Separate and thoroughly clean leaking surfaces Reapply sealant Replace parts and torque bolts to specifications Worn or damaged oil seal Replace oil seal Shifter base loose Replace shifter assembly High effort shift Reverse lockout assembly Check lockout assembly function from 5 gate to Replace parts as required reverse gate TOOLS TR 3650 TORQUE WRENCHES PULLERS BEARING AND BEARING SEPARATORS SOCKET SET 40 TORK 40 TORK PLUS FEELER GAGES BALL PEIN HAMMER SOFT FACET HAMMER PLIERS SNAP RING PLIERS HEX KEY SET GASKET ELIMINATOR DRIFT PUNCHES 60
10. 0 05 MM AS REQU 17 AR SNAP RING 2 40 0 05 MM AS REQU 18 AR SNAP RING 2 50 0 05 MM AS REQU 19 AR SNAP RING 2 60 0 05 MM AS REQU 20 12 SPRING SYNCHRONIZER 21 2 1st amp 2nd INNER RING 22 2 BLOCKER RING amp LINING ASSY 1st amp nd 23 2 1st amp 2nd BLOCKER RING 24 1 SNAP RING HUB SYNCHRO 1st amp 2nd 25 2 SNAP RING TOP INSERT 26 1 BEARING CONE amp CUP ASS Y MAIN SHAFT 27 1 BEARING 28 BEARING SHIM C S AS REQUIRED 29 BEARING SHIM G S AS REQUIRED 30 AR BEARING SHIM C S AS REQUIRED 31 AR BEARING SHIM C S AS REQUIRED 32 1 BEARING CONE amp CUP ASS V 5 33 1 CUP BEARING 34 2 ROLLER BEARING GEAR 5th C S 35 2 ROLLER BEARING GEAR REV IDLER 36 1 SPACER ROLLER BEARING GEAR REV 37 2 O RING INHIBITOR 38 1 CONE BEARING 39 1 BEARING CONE amp CUP ASS V REAR 5 40 1 CUP BEARING REAR C S 41 1 CONE BEARING REAR C S 42 1 SPACER ROLLER BEARING 5th 5 43 1 REVERSE IDLER GEAR 44 2 1st amp 2nd CLUTCH CONE 45 1 1st GEAR SPEED ASS Y M S 46 1 151 GEAR SPEED M S 47 2 BUSHING 3 GEAR amp REV 48 1 CLUTCH HOUSING ASS Y 49 1 CLUTCH HOUSING s 50 1 TRANSMISSION CASE ASS Y 51 1 TRANSMISSION CASE 52 1 EXTENSION ASS Y 53 1 EXTENSION 54 1 MAIN SHAFT 55 1 SPEEDOMETER ROTOR GEAR 56 1 OIL SEAL EXTENSION 57 1 INPUT SHAFT 58 1 3 GEAR SPEED M S 59 1 2nd GEAR SPEED ASS Y 5 60 1 2nd GEAR SPEED M S 61 1 5th GEAR SPEED 5 62 1 SYNCHRO
11. Install the countershaft bearing cone as shown shaft bearing cone as indicated 47 TR 3650 ee 4 61 Hold the cone and install the transmission case as 62 Install temporarily the transmission case as shown indicated 63 Using a 13 mm socket install the 2 two bolts that hold 64 Position a dial indicator as shown on the output shaft the case and tighten to the specified torque 18 28 Ib ft as ory on the 5 gear End play must be between 0 001 indicated 0 005 NOTE Add shims for less and play or remove shims for more endplay To add or remove shims refer to views 48 amp 50 65 Position a dial indicator as shown on the transmission case pry on countershaft End play must be between 0 001 0 005 X 43 ON 66 Install the reverse fork as shown C i F H KA i Tus TA i A A f ri 1 lh P F ir 68 Using a 5 32 inch drift and hammer install the split pin 69 Install the 3 amp 4t fork as shown on the reverse fork and shift rail 70 Install the 3 amp 4th rail as indicated 71 Using a 5 32 inch drift and hammer install the split pin 49 TR 3650 74 Using a 5 32 inch drift and hammer install the split pin from the 1 amp 2 fork and shift rail 77 Clean the mating surfaces of the transmission main case and the clutch housing Apply a bead of
12. lll Disconnect the negative battery ground cable before using any electric welding equipment CONTENTS Introduction 4 Explosive view 5 Transmission Parts 6 Specifications 7 Lubrication 8 General Information 9 Torque Recomendations 10 Axial Clearances 12 Preventive Maintenance 12 Precautions 13 Inspection List 14 Turret Control Disassembly 15 Control Parts Group Disassembly 22 Primary Gear Parts Group Disassembly 24 Secondary Group Disassembly 30 Input Shaft Disassembly 31 Case Parts Group Input Shaft Disassembly 33 Extension Disassembly 36 Reassembly Reverse Gear 38 Troubleshooting Guide 57 Tools 60 TR 3650 INTRODUCTION This manual is designed to provide detailed information necessary to service and repair the TREMEC 3650 transmission listed on the cover As outlined in the Table of Contents the manual is divided into 4 main sections a Technical Information and reference b Disassembly and reassembly of the transmission c Troubleshooting guide d Tools required The format of the manual is designed to be followed in its entirety if complete disassembly and reassembly of the transmission is necessary But if only one component of the transmission needs to be repaired see the Table of Con tents for the page numbers showing that component For example if you need to work on the Shifting Controls you will find instructions for removal disassembly and reassem bly on page into Service manuals Illustrated part list
13. 1 amp 2 Gate pin on the shift rail as shown 94 Using a 5 32 inch drift and hammer install the 34 amp 4 95 Install the 5 gear shift fork the synchronizer assembly gate pin on the shift rail the synchronizer cone and fifth gear as an assembly 53 96 Using a 5 32 inch drift and hammer install the 5 fork pin on the shift rail 98 Install the ball for speedometer using a magnet as shown l 100 Using the snap ring plier as indicated Es install the sensor snap ring 54 TR 3650 97 Using a snap ring plier install the 5 gear snap ring as indicated NT k E x p 99 Install the speedometer sensor as indicated 101 Clean the mating surfaces of the transmission main case and the extension housing Apply a bead of silicone rubber to the sealing surface of the transmission case 102 Install the extension housing and at the same time 103 Install the 12 bolts and tighten to the recommended install the gear shift off set lever torque as indicated 104 Install the fill plug as shown 105 Using a 10 mm socket tighten to 5 the recommends torque r m qa y n Ow E a ET 15 L ENTE 106 Using a 5 32 inch drift and hammer install the off set 107 Install the shift spring and plate as indicated lever pin as shown 55 110 Using a socket Install the bolt on plate as shown 1
14. 1 STUD CLUTCH RELEASE LEVER 1 2 13 UNC 2A HEX HEAD 7 8 35 50 26 36 11 1 INTERLOCK SUPPORT BOLT M10 X 1 5 6g TORX T40 20 35 15 25 12 2 GUIDE PLATE BOLT SHOULDER Ma X 1 25 6H TORX 20 35 15 25 13 1 DETENT BIAS SPRING BOLT 1 2 20 8 2 MM TORX PLUS DRIVE 20 35 15 25 APPLY TEFLON TO THREADS OF ALL CAPSCREWS BEFORE INSTALLING DEFINITIVE 10 m d 2 J t I I7 VI UD a 72 UT FIL ER d uz gd 6 HERNI TR 3650 AXIAL CLEARANCES The axial clearances will have maintain original for mainshaft gear cluster gear and 5th assembly gear DESCRIPTION ISL GEAR SPEED 2nd GEAR SPEED 3rd GEAR SPEED INPUT REVERSE GEAR GOUNTERSHAFT SIN GEAR Gio er REVERSE IDLER GEAR SPECIFICATION mm in 0 200 0 500 008 019 0 100 0 340 004 013 besten 0 125 0 365 005 014 saves 0 027 0 127 001 005 mwa 0 100 0 360 004 014 0 026 0 126 001 005 0 112 0 742 004 025 0 100 0 660 004 026 PREVENTIVE MAINTENANCE 1 CLUTCH HOUSING MOUNTING a Check all capscrews of clutch housing flange for loose ness 2 CLUTCH RELEASE BEARING NOT SHOWN a Remove
15. 12 Install the control turret assembly as shown 56 TR 3650 mc wem l 109 Using a 10 mm socket tighten to the recommended torque as indicated 111 Using a 10 mm socket tighten to the recommended torque see torque recommendations ia 113 Install the four bolts and tighten to the recommend torque as indicated TR 3650 ON VEHICLE SERVICE AND TROUBLESHOOTING PROBLEM POSSIBLE CAUSE Will not shift Control lever Moves Control lever assy broken or damaged Damaged offset lever shift plate or selector armloose rail bushings Broken roll pins in offset levers of selector arm Hard shift or control lever will not move into gear Clutch not releasing Improper or low transmission lubricant Shifter rail binding Binding of sliding synchronizers or gears If reverse only seized backup switch Worn or damaged flywheel pilot bushing Bell housing misaligned Gears clash when shifting Engine idle speed too high Clutch damaged or out of adjustment Bent shift forks or worn fork pads Damaged synchronizer Pilot bearing between input shaft and output shaft binding Bell housing misaligned Damaged gears Worn or damaged flywheel pilot bushing REMEDY Replace control lever and housing assy Hemove extension or adapter and case cover Check for damaged parts Replace damaged parts Adjust or replace clutch Add or drain and replace with proper lubricant Remove extension or adapter and
16. ER RING 3 CLUTCH CONE BALL REVERSE CLUTCH CONE M INSERT SYNCHRONIZER ASS Y NEEDLE BEARING ASS Y 3 GEAR 1 BLOCKER RING PEED ASS Y a gt T 1 GEAR SPEED SNAP RING SPEEDOMETER 1 CLUTCH CONE SPEEDOMETER m 15 amp 21 SNAP c ASSY O 1 BLOCKER RING Q h E BEARING ASS Y as 1 BLOCKER RING BALL 1 amp 2 SLEEVE SNAP RING HUB M SYNCHRO 1 amp 2 M 1 8 2 HUB SYNCHRO INSERT SYNCHRONIZER SPRING SYNCHRONIZER 8 st GEAR SPEED BEARING IN BEARING CONE THRUST WASHER fk BALL BUSHING 3 GEAR N REVERSE GEAR SPEED NEEDLE BEARING ASS Y 24 41 Install the mainshaft assembly in a support or vise 40 Remove the mainshaft assembly from the clutch equipped with soft jaws or wood shaft front facing up as housing as shown indicated N CAUTION Support the outout shaft while using the press to prevent damage to the shaft or gears LI a LI EN ki 1 1 i i k EJ 5 i 8 LAIT _ 43 Using a special tool or a press remove the fifth gear 44 Remove the locating ball as shown the spacer the output shaft bearing and reverse gear from the output shaft bearing 25 TR 3650 49 Remove the needle bearing from first gear as shown 50 Remove the first gear synchronizer inner cone as indicated va 51 Remove the outer first edi svnchronizer cone as 52 Remove the first gear svnchronizer block
17. NIZER ASS Y 5th GEAR C S 63 1 Sth GEAR C S 64 2 5th amp REVERSE SLEEVE 65 1 CLUSTER GEAR 66 4 BLOCKER RING 3 4th 5th amp REVERSE 67 1 1st amp 2nd SHIFT RAIL 68 1 3 amp 4 th SHIFT RAIL 69 1 5th amp REV SHIFT RAIL 70 1 5th FORK SHIFT ASS Y 71 1 5th FORK SHIFT 72 1 151 amp 2nd ASS Y 118 119 120 121 122 123 124 125 126 127 128 129 130 131 132 133 134 135 136 137 138 139 140 141 142 143 1st amp 2nd GATE 1st amp 2nd FORK SHIFT ASS Y 1st amp 2nd FORK SHIFT 3th amp 4th FORK SHIFT ASS Y Sth amp 4th FORK SHIFT SELECTOR RAIL ARM SELECTOR INHIBITOR SEAT SELECTOR GATE DETENT PLUG DETENT ACTUATING SPRING REVERSE FORK SHIFT ASS Y REVERSE FORK SHIFT 3 amp 4th GATE SHIFTER LEVER ASS Y SPACER FONT THRUST WASHER 3 GEAR amp REV 36 amp 4th SYNCHRONIZER ASS Y 3 amp 4th SLEEVE 1st amp 2nd SYNCHRONIZER ASS Y 1st amp 2nd SLEEVE SYNCHRONIZER ASS Y REVERSE GEAR REVERSE CLUTCH CONE CLUTCH CONE 5th SPEED C S SPRING BASE TURRET RAIL REVERSE INHIBITOR INHIBITOR REVERSE PIN INHIBITOR RETAINER BAR INTERLOCK SUPPORT OIL SEAL BEARING RETAINER WASHER SPRING RETENTION GEAR REVERSE M S THRUST WASHER 5th GEAR C S REVERSE SHAFT RAIL BOLT M8X1 25X60 TORX BOTTON HEAD REVERSE SUPPORT SHAFT O RING INSERT SYNCHRONIZER 3 CLUTCH CONE i 3 GEAR SPEED ASS Y M S 1st amp 2nd HUB SYNCHRO 3 amp 4t
18. NOTES 1 Lengths measured from clutch housing face to cover rear extension 2 Weights include shift bar housing clutch housing less shift lever assembly and clutch parts For more information on available application see the transmission s illustrated parts list All weights are approximate 3 Oil capacities are approximate depending on inclination of engine and transmis sion Always fill transmission with proper grade and type of lubricant to level of filler opening See LUBRICATION TR 3650 Proper lubrication procedures are the key to a good all Thus all parts are amply lubricated if these procedures are around maintenance program closely followed If the oil is not doing its job or if the oil level is ignored all the maintenance procedures in the world are not going to keep the transmission running or assure long transmission 1 Maintain oil level Inspect regularly life 2 Change oil regularly TREMEC Transmissions are designed so that the internal parts operate in an oil circulating bath by the motion of the 3 Use the correct grade and type of oil gears and shafts 4 Buy from a reputable dealer OIL SPECIFICATIONS MODEL API SPECIFICATION TREMEC OIL TRANSMISSION SPECIFICATION CAPACITY Dexron III 1300 244 006 CHANGE AND INSPECTION OF THE LUBRICANT PROPER OIL LEVEL Use oil ET M99 specification Additives and friction modifiers are not recommended for use in transmission TR 3650 PROPER OIL LEVEL Make s
19. all 39 Using a magnet Install the ball use grease to hold the 40 Install the thrust washer Be sure to align the slot in the ball in place washer with the ball 41 Instal the bearing cone as shown 42 Use a special tool or a press to install as indicated 44 Lon 45 Using a snap ring plier install the 5 gear snap ring 46 Using a special tool or press install the countershaft as Indicated bearing cone as shown 78 AM OS A 47 Using a special tool install the input shaft seal 48 Install the appropriate shims to achieve the proper end plav this total gives vou a shim pack thickness to start the end plav measurement 45 TR 3650 i i Ae AT 50 Install the appropriate shims to achieve the proper end play this total gives you a shim pack thickness to start the end play measurement 49 Install the front countershaft bearing cup as indicated 51 Install the front input shaft bearing cup as indicated 52 Using a special tool or press install input shaft bearing cone as shown 53 Install the input shaft needle bearing as indicated 54 Install the input shaft bearing as shown aa 55 Install the synchronizer blocking ring as indicated P s j EE ET ai NE E a E mt 57 Install the countershaft as indicated 59 Install a tube as a guide when installing the counter 60
20. all bearings in clean solvent Check balls rollers and raceways for pitting discoloration and spalled areas Replace bearings thar are pitted discolored spalled or damaged during disassembly 2 Lubricate bearings that are not pitted discolored or spalled and check for axial and radial clearances 3 Replace bearings with excessive clearances 4 Check bearing fit Bearing inner races should be tight to shaft outer races slightly loose in case bore If bearing spins freely in bore case should be replaced B GEARS 1 Check gear teeth for frosting and pitting Frosting of gear teeth faces present no threat of transmission failure Often in continued operation of the unit frosted gears heal and do not progress to the pitting stage In most cases gears with light to moderate pitted teeth have considerable gear life remaining and can be reused but gears with advanced stage pitting should be replaced 2 Check for gears with clutching teeth abnormally worn tapered or reduced in length from clashing in shifting Replace gear found in any of these conditions 3 Check axial clearance of gear Where excesive clearance is found check gear snap ring split washer clutch hub and gear hub for excessive wear C SPLINES 1 Check splines on all shafts for abnormal wear if sliding clutch gears companion flage or clutch hub have worn into the sides of the splines replace the specfic shaft affected
21. case cover Check for damaged parts Replace damaged parts Remove extension and case to check that synchronizers and gears slide freely on shafts Remove and replace damaged parts Remove and check backup switch Replace if seized Replace pilot bushing Align bell housing to within 0 010 inch TIR on face and in bore Adjust idle speed to specifications Adjust or replace clutch Disassemble and check Replace damaged parts Disassemble and check for damaged synchronizer parts Replace damaged parts Disassemble and check bearing rollers input shaft ID and output shaft OD Replace dam aged parts Align bell housing to within 0 010 inch TIR on face and in bore Disassemble and check for gear damage Replace damaged gears Replace pilot bushing 5888585858 TIS TR 3650 PROBLEM Transmission jumps out of gear Transmission locked one gear Transmission noise NOTE Make sure noise is coming from transmission and not clutch release bearing or other components POSSIBLE CAUSE Synchronizer damaged or excessively worn Blocking ring damaged worn index slots or friction surfaces worn or damaged Excessive countershaft end play Shifting fork loose on shift rail worn or damaged fork or fork pads Fork or offset lever loose on shift rail Worn or damaged forks offset lever shift rail broken roll pins in offset levers Worn or damaged synchronizer Worn or damaged gears Improper or low transmis
22. chronizer inner cone as shown indicated 17 Install the second gear needle bearing lubricate with 18 Install the 2 speed gear as indicated rotate the gear the recommended transmission fluid to align gear slots with inner cone tabs 40 NEN 21 Using a special tool or a press install the spacer thrust washer and second speed gear as shown 23 Install the third speed gear as indicated 20 Install the thrust washer as indicated d 1 r 22 Install the third gear needle bearing lubricate with the recommended transmission fluid as shown 24 Install the 3 speed synchronizer blocking ring as shown 41 TR 3650 25 Install the 3 amp 4 speed synchronizer as indicated 26 Using a snap ring plier install the 3 amp 4t hub snap ring as shown 2 Install the input shaft bearing race as indicated 28 Install the first gear synchronizer blocking ring align the blocking ring tabs with the synchronizer assembly Rotate mainshaft with synchronizer up as shown 29 Install the outer first gear synchronizer cone as 30 Install the inner first gear synchronizer cone rotate the shown inner cone till it is seated as indicated 42 TR 3650 37 Install reverse gear needle bearing lubricate with the 38 Install reverse gear rotate gear to align the gear slots recommended transmission fluid as shown with the inner cone tabs
23. h HUB SYNCHRO 5th amp REV HUB SYNCHRO BALL BALL SPEEDOMETER DRAIN PLUG amp FILLER PLUG BREATHER 2nd amp 3 NEEDLE BEARING ASS Y BEARING TAPERED ROLLER CUP BEARING TAPERED ROLLER CONE CAP SCREW HEX HEAD SENSOR SWITCH ASS Y BACKUP LAMP TUB RETAINER BEARING DOWEL PIN BUSHING EXTENSION HOUSING STUD CLUTCH RELEASE LEVER SEAL OUTPUT SPLINE BEARING SHIM 0 55 0 013 MM BEARING SHIM 0 61 0 013 MM BEARING SHIM 0 66 0 013 MM BEARING SHIM 0 71 0 013 MM BEARING SHIM 0 76 0 013 MM BEARING SHIM 0 81 0 013 MM BEARING SHIM 0 83 0 013 MM SNAP RING SPRING CENTERING SHIFT CONTROL BOLT SHOULDER BOLT METRIC HEX WASHER HEAD BOLT METRIC HEX WASHER HEAD PAD SHIFT FORK SENSOR SPEEDOMETER SOLD ONLY IN ASS Y aa SPECIFICATIONS The transmissions series TR 3650 have five forward speeds and one reverse of advanced design that offers to you the most efficent relation of capacity of partorsion weight that any other transmissions of 5 speeds within its rank IMPORTANT All TREMEC transmissions TR 3650 are identified by the model and serial number and date This information is stamped on the transmission identifi cation tag and affixed to the case TRANSMISSION MODEL ASSEMBLY DATE TRANSMISSION NUMBER SERIAL NUMBER kejo GEAR RATIOS 151 2 4th oth REV OIL CAPACITY TR 3650 1 2 3 38 2 00 1 32 1 00 0 67 3 38 3800 C C TR 3650 3 4 5 3 38 2 00 1 32 1 00 0 62 3 38 3800 C C
24. hand hole cover and ckeck radial and axial clearance in release bearing b Check relative position of thrust surface of release bearing with thrust sleeve on push type clutches 3 CLUTCH PEDAL SHAFT AND BORES a Pry upward on shafts to check wear b b If excessive movement is found remove clutch release mechanism and check bushings in bores and war on shafts 4 LUBRICANT a Change at specified service intervals b Use only the types and grades as recommended See LUBRICATION 5 FILLER AND DRAIN PLUGS a Remove plug filler and check level of lubricant at speci fied intervals Tighten filler and drain plugs securely 6 CAPSCREW a Check all capscrew especially those turret the clutch housing and cover rear for looseness which can cause oil leakage See TORQUE RECOMMENDATIONS 7 GEAR SHIFT LEVER a Check for looseness and free play in housing If lever is loose in housing proceed with check No 8 8 GEAR SHIFT LEVER HOUSING ASSEMBLY a Remove the gear shift housing assembly from transmis sion b Check gear shift lever botton end for wear of slots Also check finger assembly for wear 12 9 UNIVERSAL JOINT COMPANION FLAGE OR YOKE NUT a Checkfor tightness Tighten to recommended torque rating 10 OUTPUT SHAFT NOT SHOWN a Pry upward against output shaft to check radial clear ance in mainshaft rear bearing CHECK WITH UNIVERSAL JOINT COMPANION FLAGE OR YOKE REMOVED NOTE If necessary use sol
25. ing ring as shown indicated MM Y 53 Rotate the output shaft with the input end facing 54 With a snap ring plier remove the hub snap ring as upward and remove the input shaft bearing race as shown indicated D m 1 55 Remove the 3rd amp 4th speed synchronizer as shown 56 Remove the 3 speed synchronizer blocking ring as indicated 27 TR 3650 5 Remove the third speed gear as shown NOTE Install the special tool behind second gear with the flat side of the tool facing second gear 59 Using a special tool or a press remove the spacer thrust washer and second speed gear 60 Remove the locating ball as shown 61 Remove the second speed gear needle bearing as indicated 28 62 Remove the second speed gear synchronizer inner 63 Hemove the second speed gear synchronizer outer cone as shown cone as indicated 64 Remove the second speed gear synchronizer blocker 65 Using a snap ring pliers remove the 3 amp 4t hub snap ring as shown ring as indicated 66 Using a special tool or a press remove the 3rd amp 4th Synchronizer as shown E 2 9 TR 3650 SECONDARY GROUP DISASSEMBLY SPACER 5 GEAR C S BALL THRUST waa i BEARING TAPERED BEARING TAPERED ROLLER ASS V g ROLLER BEARING TAPERED ROLLER CONE COUNTER GEAR BEARING TAPERED ROLLER ASS Y SPACER 5 SLEEVE INSERT SYNCHRO
26. n At 22 Remove the two needle bearings and the spacer as indicated 23 Using a magnet remove the ball as shown 24 Remove the thrust washer as indicated EN 19 TR 3650 FE c bd E AN A 25 Remove the two bolts from the shift interlck palte as 26 Remove the shift interlock plate as indicated shown 28 Position the interlock and lock pin on the center rail two between the rails N CAUTION Do not remove all bolts while the horizontal position 29 Rotate the transmission to a horizontal position Remove 12 bolts leaving two opposing bolts in Rotate the transmission to a vertical position them remove the remaining two bolts 20 30 Carefully the clucht housing from the transmission main case as shown 31 Remove the trnsmission case from the clucht housing as indicated Use a hook to hold the bearing cone to avoid interference with the cluster gear EN 21 TR 3650 CONTROL PARTS GROUP DISASSEMBLY ROLLER BEARING SPACER FRONT SEAT SELECTOR i 15 amp 2 GATE ASS Y amp st amp DND FORK SHIFT SELECTOR RAIL j NYLON STOP ins PAD 15 amp 2 GATE ROLL PIN ROLL PIN e n 3 amp 4 GATE _ ARM SELECTOR INHIBITOR N SPACER FRONT i ROLLER BEARING 1 amp 2 SHIFT cr SHIFT NYLON STOP amp 4 FORK 3 amp 4 FORK SHIFT ASS Y
27. p rings with pliers designed for this purpose Snap rings removed in this manner can be reused if they are not sprung or loose 4 CLEANLINESS Provide a clean place to work It is important that no dirt or foreign material enters the unit during repairs Dirt is an abrasive and can damage bearings It is always good practice to clean the outside of the unit before starting the planned disassembly 5 WHEN USING TOOLS TO MOVE PARTS Always apply force to shafts housings etc with restraint Movement of some parts is restricted Never apply force to the part being driven after it stops solidly The use of soft hammers bar and mauls for all disassem bly work is recommended EN 13 TR 3650 Before reassembling the transmission check each part carefully for abnormal or excessive wear and damage to determine reuse or replacement When replacement is necessary use only genuine TREMEC Transmission parts to assure continued performance and extended life from your unit Since the cost of a new part is generally a small fraction of the total cost of downtime and labor avoid reusing a questionable part which could lead to additional repairs and expense soon after reassembly To aid in determining the reuse or replace ment of any transmission part consideration should also be given to the unit s history mileage application etc Hecommended inspection procedures are provided in the following check list A BEARINGS 1 Wash
28. rshaft gear Torque is transferred to engaged mainshaft gear The cross section illustrates 1st speed gear position Engaged mainshaft gear internal clutching teeth transfers torque to mainshaft through synchronizer assembly Mainshaft transfers torque directly to driveshaft t through rear yoke a etus TORQUE RECOMENDATIONS TR 3650 Correct torque application is important to assure long wrench to obtain recommended torque ratings Do not transmission life Over or under tightening of fasteners can torque capscrews dry Apply teflon to threads of all result in a loose installation and in many instances can capscrews before in installing definitive eventually cause demage to the transmission Use a torque 000 000 c Qu l kal Herz A 10 EE ITEM QTY DESCRIPTION 91116101 Lbs Ft 1 3 DETENT PLUGS 1 2 20 8 2 MM TORX PLUS DRIVE 20 35 15 25 2 14 CLUCTH HOUSING TO TRANSMISSION MAIN CASE BOLT 25 40 19 29 M8X1 25 HEX HEAD 13 3 12 EXTENSION TO TRANSMISSION MAIN CASE BOLT 25 40 19 29 M8X1 25 HEX HEAD 10 MM 4 4 GEARSHIFT LEVER TO EXTENSION HGS BOLT 25 40 19 29 M8 X 1 25 HEX HEAD 10 MM 5 1 REVERSE LIGTH SWITCH M16 X 1 5 HEX HEAD 7 8 20 35 15 23 6 1 SENSOR SPEEDOMETER BOLT M6 X 1 00 HEX HEAD 10 MM 7 14 5 10 Fi 1 FILL PLUG 1 2 14NPTF SOCKET HEAD 3 8 20 35 15 25 8 1 DRAIN PLUG 1 2 14 NPTF SOCKET HEAD 3 8 20 35 15 25 9 1 REVERSE IDLER GEAR BOLT Ma X 1 25 TORX PLUS 20 35 15 25 10
29. s 77 Remove the bearing shim from the counter shaft as shown indicated 79 Remove the reverse idler shaft bolt Remove and discard the seal as indicated 81 Remove the reverse gear the shaft and support shaft 80 Remove the reverse idler gear assembly as shown as indicated 34 82 Remove the reverse idler gear bearing The reverse idler gear is three separate pieces bearing spacer bearing as shown a L l L EC F ax k i ka Ia a wel E l 83 Remove the reverse switch as indicated en 55 TR 3650 EXTENSION DISASSEMBLY DETENT PLUG SEAL OUTPUT SPLINE OIL SEAL EXTENSION WASHER SPRING RETENTION 1 1 BOLT SHOULDER SPRING CENTERING Da SHIFT CONTROL SPRING BASE TURRET BUSHING EXTENSION PIN INHIBITOR FILLER PLUG m PIN DOWELL A QF BOLT METRIC O RING SPRING INHIBITOR B o ke RAIL REVERSE INHIBITOR M EXTENSION E CAP SCREW HEX HEAD SENSOR SENSOR SPEEDOMETER INHIBITOR REVERSE PIN DOWELL MAGNET 84 Remove the fifth amp reverse inhibitor bolt as shown 85 Remove the fifth amp reverse lockout inhibitor as indi cated 36 Jn g E il f EL
30. silicone rubber to the sealing surface on the clutch housing then install the transmission main case 50 y A J N kd M BIE ms P 78 Install the transmission case as shown 79 Using a 13 mm socket install the 14 bolts and tighten to the recommended torque l _ 98 AE LE Pr ER o U n l l n E ks Um b i _ _ m ka ji E 81 Using a magnet install the lock pin in the center rail as shown a z Lil 82 Using a magnet install the interlock pins as indicated 83 Install the shift interlock plate as shown 51 TR 3650 A J L 4 a E pa 4 3 T T T i m i l win HET n ow a m d z a J f Pi E E x h Fu i m L LI e p i l E a m i l E il E E gt A TEL E 1 2 l l a i _ i l o z a n LE FL e 15 m 84 Install the shift interlock plate bolts as indicated 85 Tighten to the recommended torque ta 87 Install the thrust washer as shown 88 Install the two needle bearing and spacer as indicated 89 Install the plastic spacer as shown 52 EN 90 92 Using a 5 32 inch drift and hammer install the
31. sion lubricant Loose bolts or other attaching parts Improper flywheel housing to engine crankshaft alignment Noisy transmission bearings Noisy gears REMEDY Disassemble and check for worn or damaged synchronizer parts Replace damaged parts Disassemble and check blocking ring for wear or damage Replace worn or damaged parts Disassemble and check Replace worn or damaged parts Reshim if necessary Disassemble and check for wear or damage Replace worn or damaged parts Remove extension and case to check for loose parts on shift rail Replace roll pin s If still loose replace shift rail and or attached parts as required Remove extension or adapter and case cover Check for wear or damage Replace damaged parts Disassemble and check for worn or damaged synchronizer parts Replace worn or damaged parts Disassemble and check for worn or damaged gears Replace worn or damaged gears Add or drain and replace with proper lubricant Make sure all attaching parts are torqued to specifications Check alignment and correct if necessary per vehicle service manual Disassemble and check bearings bearing rollers and parts in and on which they operate for wear or damage Replace worn or damaged parts Disassemble and check for worn or damaged gears including speedometer gear Replace worn or damaged gears PROBLEM POSSIBLE CAUSE REMEDY Transmission leakage Leakage from other components Verify transmission leakage
32. tions as listed below during reassembly 1 GASKET ELIMINATOR Use gasket eliminator in all the transmisi n the omisi n de any bead of silecone rubber to the sealing surface can cause result in oil leakage Use only products approved by TREMEC 2 CAPSCREWS To prevent oil leakage and loosening use teflon sealant thread all capscrews For recommended torque ratings see TORQUE RECOMMENDATIONS 3 ASSEMBLY See the illustrations provided in the detailed disaddembly instruvtions as a guide to reassembly 4 INITIAL LUBRICATION Coat all thrust washers synchronizer and bearings with transmission lubricant during reassembly to prevent dam age during initial star up 5 AXIAL CLEARANCES Maintain original axial clearances for mainshaft gears See especification axial clearances 6 BEARINGS Using a sleeve type driver that contacts the bearing inner race prevents damage to the rollers and cage 7 SHIMS Use shims new until obtaining end play specified the recorded end play measurements select and install the appropriate shims to achieve the proper end play IMPORTANT See the appropriate illustrated parts list specified by model series to ensure that proper parts are used suring reassembly of the transmission TURRET CONTROL DISASSEMBLY BOLT METRIC HEX WASHER HEAD SHIFTER LEVER ASS Y 15 DISASSEMBLY TRANSMISSION TR 3650 2 Turn out the four bolts and remove as shown pe
33. ure oil is level with the filler opening Because you can reach oil with your finger does not mean oil is at proper level DRAINING OIL Drain transmission while oil is warm To drain oil remove IMPROPER OIL LEVEL the drain plug at case bottom Clean the drain plug before re installing OIL CHANGE AND REFILLING Clean case around filler plug and remove plug from case side Fill the transmission to the level of the filler opening The exact amount of oil depends on the transmission inclination and model Do not over fill this causes oil to be forced out of the case and cause a deficients lubrication when adding oil types and brands of oil should not be mixed because of possible incompatibility GENERAL INFORMATION The TR 3650 transmissions have five forward speeds and one reverse and are shifted as you would shift any synchronized transmission manual following the simple 5 speed shift pattern Follow the simple 5 speed shift pattern JUL NEUTRAL JUL POWER FLOW The transmission must efficiently transfer the engine s power in terms of torque to the vehicle s rear wheels Knowl edge of what takes place in the transmission during torque tranfer is essential when troubleshooting and making repairs 1 Power torque from the engine is transferred to the input shaft and drive gear 2 Torque is transferred to the countershaft drive gear Torque is delivered along the countershaft to all counte
34. vent and shop rag to clean sealing surface of companion flage or yoke DO NOT USE CROCUS CLOTH EMERY PAPER OR OTHER ABRASIVE MATERIALS THAT WILL MAR SURFACE FINISH 11 SPLINES ON OUTPUT SHAFT NOT SHOWN a Check for wear from movement and chucking action of the universal joint companion flange or yoke 12 MAINSHAFT REAR BEARING COVER a Check oil seal for wear PRECAUTIONS lt is assumed in the detailed assembly instructions that the lubricant has been drained from the transmission the necessary linkage disconnected and the transmission has been removed from vehicle chassis Removal of the gear shift lever housing assembly is in cluded in the detailed instructions Disassembly and Reassembly Shifting Controls however this assembly must be detached from shift bar housing before transmis sion can be removed Follow closely each porcedure in the detailed instructions making use of the text illustrations and photographs provided 1 BEARINGS Carefully wash and relubricate all reuseable bearing as removed and protectively wrapped until ready for use Remove bearings planned to be reused with pullers de signed for this purpose 2 ASSEMBLIES When disassembling the various assemblies such as the mainshaft countershafts and shift bar housing lay all parts on a clean bench in the same orden as removed This procedure simplifies reassembly and reduces the possibility of losing parts 3 SNAP RINGS Remove sna
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